EP1439569B1 - Lampe a décharge comprenant un socle et procédé et fixation pour sa fabrication - Google Patents

Lampe a décharge comprenant un socle et procédé et fixation pour sa fabrication Download PDF

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Publication number
EP1439569B1
EP1439569B1 EP04250003A EP04250003A EP1439569B1 EP 1439569 B1 EP1439569 B1 EP 1439569B1 EP 04250003 A EP04250003 A EP 04250003A EP 04250003 A EP04250003 A EP 04250003A EP 1439569 B1 EP1439569 B1 EP 1439569B1
Authority
EP
European Patent Office
Prior art keywords
envelope
clamp ring
plastic lining
lamp base
lamp
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
EP04250003A
Other languages
German (de)
English (en)
Other versions
EP1439569A3 (fr
EP1439569A2 (fr
Inventor
Istvan Mudra
Pal Garamvolgyi
Szabolcs Bella
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
General Electric Co
Original Assignee
General Electric Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by General Electric Co filed Critical General Electric Co
Publication of EP1439569A2 publication Critical patent/EP1439569A2/fr
Publication of EP1439569A3 publication Critical patent/EP1439569A3/fr
Application granted granted Critical
Publication of EP1439569B1 publication Critical patent/EP1439569B1/fr
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J5/00—Details relating to vessels or to leading-in conductors common to two or more basic types of discharge tubes or lamps
    • H01J5/50—Means forming part of the tube or lamps for the purpose of providing electrical connection to it
    • H01J5/54—Means forming part of the tube or lamps for the purpose of providing electrical connection to it supported by a separate part, e.g. base
    • H01J5/58—Means for fastening the separate part to the vessel, e.g. by cement
    • H01J5/60—Means for fastening the separate part to the vessel, e.g. by cement for fastening by mechanical means
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J5/00—Details relating to vessels or to leading-in conductors common to two or more basic types of discharge tubes or lamps
    • H01J5/50—Means forming part of the tube or lamps for the purpose of providing electrical connection to it
    • H01J5/54—Means forming part of the tube or lamps for the purpose of providing electrical connection to it supported by a separate part, e.g. base
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J5/00—Details relating to vessels or to leading-in conductors common to two or more basic types of discharge tubes or lamps
    • H01J5/50—Means forming part of the tube or lamps for the purpose of providing electrical connection to it
    • H01J5/54—Means forming part of the tube or lamps for the purpose of providing electrical connection to it supported by a separate part, e.g. base
    • H01J5/58—Means for fastening the separate part to the vessel, e.g. by cement
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J61/00—Gas-discharge or vapour-discharge lamps
    • H01J61/02—Details
    • H01J61/30—Vessels; Containers
    • H01J61/34—Double-wall vessels or containers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J61/00—Gas-discharge or vapour-discharge lamps
    • H01J61/02—Details
    • H01J61/36—Seals between parts of vessels; Seals for leading-in conductors; Leading-in conductors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J61/00—Gas-discharge or vapour-discharge lamps
    • H01J61/84—Lamps with discharge constricted by high pressure
    • H01J61/86—Lamps with discharge constricted by high pressure with discharge additionally constricted by close spacing of electrodes, e.g. for optical projection

Definitions

  • This invention relates to a discharge lamp, particularly a high pressure automotive headlight discharge lamp with an arrangement for fixing an envelope of the lamp to a lamp base.
  • the invention further relates to a method for manufacturing such a discharge lamp.
  • a wide variety of automotive high pressure discharge lamps are known in the art. These lamps normally comprise a relatively small discharge vessel surrounded by a larger envelope. The envelope is sealed around the discharge vessel, creating a monolithic discharge vessel-envelope assembly. The light of the lamp is generated by a discharge arc between two electrodes, producing a small light spot with very high luminous intensity. The light spot of the lamp is subject to strict positioning tolerances in order to keep the prescribed optical parameters of the headlight, into which the discharge lamp is installed. The light spot of the discharge vessel is positioned by adjusting the complete discharge vessel-envelope assembly into a proper position relative to a lamp base of the lamp and fixing the envelope (and thereby also the discharge vessel) in the adjusted position.
  • the envelope is held in the adjusted position relative to the lamp base using various solutions.
  • the envelope is held in place with the help of an outer end of the envelope, which extends beyond the sealing area between the discharge vessel and the envelope.
  • This outer end of the envelope extends into a plastic holder portion of the lamp base, and the holder portion is melted around the outer end of the envelope.
  • the melting of the holder portion is done with high frequency induced heating, and for this purpose, metal inserts are provided in the plastic holder portion.
  • the holder portion itself is also melt sealed relative to the external shell of the lamp base.
  • the metal inserts have no further role in the lamp, but only to facilitate the heating of the plastic parts.
  • the problem with this fixing method is that the envelope inevitably develops stress around the indented portions at the sealing to the discharge vessel, and tends to break at these indented portions due to excessive vibration and similar mechanical loads.
  • the clamp ring is a closed ring to ensure sufficient clamping force around the envelope.
  • the clamp ring in order to ensure a certain degree of flexibility of the metal clamp ring, the clamp ring must be provided with slight undulations in a circumferential direction. These undulations allow for natural differences between the diameters of the tubular envelopes due to usual manufacturing tolerances. The undulations also take up a part of the stress when the glass envelope expands under increased temperatures. However, these undulations also allow a certain degree of deflection of the envelope, particularly under shock and vibration during normal use of the lamp, for example in an automotive headlight. This deflection of the envelope may cause a degradation of the optical parameters of the headlight.
  • a discharge lamp which comprises a discharge vessel sealed in a tubular envelope.
  • the lamp also comprises a lamp base covering an end part of the envelope and fixing means for providing a substantially rigid fixing of the envelope to the lamp base.
  • the fixing means comprises a metal clamp ring surrounding a part of the envelope external to the lamp base.
  • a melt plastic lining is provided between the clamp ring and the envelope. The melt plastic lining substantially completely fills a space between the envelope and the clamp ring.
  • a method for manufacturing a discharge lamp comprising a discharge vessel sealed in a tubular envelope, and a lamp base covering an end part of the envelope.
  • Such lamps also have fixing means for providing an essentially rigid fixing of the envelope to the lamp base, where the fixing means comprises a metal clamp ring surrounding a part of the envelope external to the lamp base.
  • the method comprises the provision of a space between the clamp ring and the envelope and the provision of a hot-melt plastic lining in the space between the clamp ring and the envelope.
  • the plastic lining is melted and substantially completely fills the space between the clamp ring and the envelope, providing a stable mechanical connection between the clamp ring and the envelope.
  • a fixture arrangement for fixing an envelope of a discharge lamp to a lamp base.
  • the fixture arrangement comprises a metal clamp ring for surrounding a part of a tubular envelope, and legs attached to the clamp ring with one end. Another end of the legs extend away from the clamp ring, for insertion into a lamp base.
  • the clamp ring comprises a hot-melt plastic lining, which may be melted to form a melt connection between the clamp ring and a lamp envelope inserted into the clamp ring.
  • the hot-melt plastic lining between the clamp ring ensures a stable and substantially deflection-free support of the lamp envelope.
  • the plastic lining can take up the mechanical stress between the clamp ring and the envelope as the latter expands due to the high operating temperature of the discharge chamber.
  • an advantageously stable support is provided, firstly because the envelope is held close to its centre of gravity, secondly because the envelope is held between the two sealed portions, so the mechanical stress - particularly the bending stress - on the sealed portions is low. Since the plastic lining completely fills the space between the clamp ring and the envelope, practically no deflection occurs as a result of a relative movement between the clamp ring and the envelope.
  • the suggested fixation method requires only a very small amount of a suitably heat resistant hot-melt plastic material.
  • the clamp ring itself can serve as the metal component for a HF induced heating of the plastic lining, and no additional elements are needed in the discharge lamp structure.
  • a high pressure discharge lamp 1 for automotive purposes This is a so called D2 type lamp, which has a sealed discharge vessel 2.
  • the discharge vessel 2 consists of a discharge chamber 21, and an upper end part 22 and a lower end part 23. These latter are sealed, so that a suitable high pressure gas atmosphere is maintained in the discharge chamber 21, for example a xenon atmosphere of 8-10 bar.
  • the end parts 22 and 23 enclose electrodes 24,25 and lead wires 26,27.
  • the lead wires 26,27 are connected to the electrodes 24,25 through molybdenum foils, in a known manner.
  • the upper lead wire 26 connects to a first contact 31 through another connecting wire 28, while the lower lead wire 27 connects to a second contact 32 directly.
  • the connecting wire 28 is insulated by a sheath 29, e.g a steatite tube.
  • the contacts 31,32 are mechanically supported by the lamp base 5, which latter also supports the discharge vessel 2, as will be explained below.
  • the contacts 31,32 are welded or soldered to the ends of the connecting wire 28 and the lead wire 27, respectively.
  • the discharge vessel 2 is surrounded by an external envelope 4.
  • the envelope 4 is substantially tubular, and it is sealed around the discharge vessel 2 at indented sealing portions 11 and 12. This creates a closed volume 13 between the discharge vessel 2 and the envelope 4, which normally contains air or nitrogen gas.
  • the sealing also provides a rigid mechanical connection between the discharge vessel 2 and the envelope 4, so that the discharge vessel-envelope assembly functions as a single structural unit in the mechanical construction of the lamp 1.
  • the discharge vessel-envelope assembly is mechanically fixed to the lamp base 5 by suitable fixing means.
  • the purpose of these fixing means is to provide a substantially rigid fixing of the discharge vessel 2 and the envelope 4 to the lamp base 5, for the reasons mentioned above.
  • the term "substantially rigid” indicates that this fixation should be as rigid as possible, and it is intended to minimize the relative movement between the discharge chamber 21 and the reference points of the lamp base 5, such as the surface 51, or the central axis A of the lamp base 5 as defined by the cylindrical surface 52.
  • the fixing means of the lamp 1 comprises a metal clamp ring 6 surrounding a part of the envelope 4 external to the lamp base 5.
  • the clamp ring 6 clamps around a part of the envelope 4 that stands out from the lamp base 5, and in this manner, the clamp ring 6 itself is also outside the lamp base 5. As best seen in Figs. 1 and 2 , the clamp ring 6 clamps the envelope 4 in a region between the two sealing portions 11 and 12, namely closer to the lower sealing portion 12, and sufficiently far from the discharge chamber 21, so that the emission of light by the discharge arc in the discharge chamber 21 is substantially undisturbed by the clamp ring 6.
  • the clamp ring 6 is fixed to the lamp base 5 with a number of tongue-like metal legs 61, typically four.
  • the legs 61 are welded to an external surface portion of the clamp ring 6.
  • Such an embodiment is shown in Figs. 1 and 2 .
  • the legs 61 may be integral with the clamp ring 6, i.e. they may be formed from the same body of material, such as a sheet metal by, for example, a cutting and pressing operation.
  • the lamp base 5 may be molded around an end of the metal legs 61, so that they are firmly embedded in the material of the lamp base 5.
  • the legs 61 may extend from a base ring 61', which is completely enclosed by the material of the lamp base 5, as illustrated in Fig. 2 .
  • the ends of the metal legs 61 may be pressed into corresponding receiving slots (not shown) of the lamp base. This allows a more economic production of the plastic body of the lamp base.
  • a melt plastic lining 7 is provided between the clamp ring 6 and the envelope 4.
  • the melt plastic lining 7 substantially completely fills the space between the envelope 4 and the clamp ring 6, and a melt connection is established therewith.
  • the plastic lining 7 fills the gap between the external surface portion of the envelope 4 and the internal surface of the clamp ring 6.
  • the plastic lining 7 is made of a suitably heat-resistant material, which withstands temperatures as high as 240-260 °C.
  • Such materials are readily available in commerce, for example polyether-ether-ketone (PEEK) materials, sold under the trade name Victrex®. These have a softening temperature which is higher than 260 °C. The melting temperature of this material is approx. 340 °C.
  • the inner diameter D c of the clamp ring 6 is positively larger than the corresponding outer diameter D e of the envelope 4.
  • the space between the envelope 4 and the clamp ring 6, and thereby also the plastic lining 7 substantially completely surrounds the envelope 4.
  • the plastic lining 7 also acts as a cushion between the glass envelope 4 and the metal clamp ring 6, and provides a more even distribution of the clamping force around the envelope 4, as compared with a direct metal-glass contact.
  • the plastic lining 7 is melted around the envelope 4 during the production of the lamp 1.
  • the various manufacturing steps are essentially the same as with the known manufacturing methods.
  • a discharge vessel-envelope assembly is prepared, which is mechanically fastened to a lamp base, and the electric contacts between the discharge electrodes and the contact members of the lamp base are established.
  • the final mechanical fastening or fixation of the envelope relative to the lamp base is performed after adjusting the position of the discharge chamber or the discharge arc relative to certain reference points of the lamp base. The only difference is in the way that the envelope is mechanically fixed in the adjusted position.
  • a space is provided between the clamp ring 6 and the envelope 4, by selecting the inner diameter D c of the clamp ring 6 larger than the outer diameter D e of the envelope 4, as explained above.
  • a hot-melt plastic lining 7 is inserted in the space between the clamp ring 6 and the envelope 4. The plastic lining 7 is melted, so that it completely fills the space between the clamp ring and the envelope.
  • the melting of the plastic lining 7 may be effected in a number of ways, for example with infrared radiation, a directed heating flame or HF electromagnetic field.
  • the last solution is particularly suitable, because the metal clamp ring 6 may be readily exploited for this purpose, and the envelope 4 itself will not be heated excessively.
  • the plastic lining 7 is typically heated to a temperature of 350-500 °C.
  • the complete heating process of the plastic lining 7 is very fast, requiring only a few seconds.
  • the molten plastic rapidly cools, and shrinks slightly during cooling, providing a strong clamping around the envelope 4.
  • the position of the envelope 4 is adjusted relative to the lamp base 5 before melting the plastic lining 7.
  • the adjusted position of the envelope relative to the lamp is retained during the cooling period of the plastic lining 7, so that an unintentional misalignment of the envelope 4 and thereby that of the discharge vessel 2 during cooling is prevented.
  • the melting of the plastic lining 7 is done while the envelope is securely held in its adjusted, proper position, which is permanently fixed when the plastic lining 7 cools and hardens again.
  • the electrical connections between the contacts 31,32 and the lead wires 26,27 may be completed both before and after the adjustment of the envelope 4 and the melting of the plastic lining 7.
  • the lamp 1 is manufactured using a bulb fixture arrangement which comprises a metal clamp ring 6 for surrounding a part of a tubular envelope, and legs 61 attached to the clamp ring 6 with one end and another end 62 of the legs 61 extending away from the clamp ring 6.
  • the extending ends 62 are intended for insertion into a lamp base 5.
  • the clamp ring 6 comprises a hot-melt plastic lining 7, which may be melted around the envelope, thereby fixing it relative to the clamp ring 6 and indirectly relative to the lamp base which receives the extending ends 62 of the legs 61 of the fixture arrangement.
  • Such a fixture arrangement 100 is shown by itself in Fig. 4 ., in a slightly different embodiment as compared with that shown in Figs. 1 to 3 .
  • the legs 61 may be welded to the clamp ring 6, (as shown in Figs. 2 and 4 ), or the legs may be integral with the clamp ring (not shown).
  • the fixing method using the plastic lining may be readily integrated into existing lamp manufacturing lines, without negatively affecting cycle time or other production parameters.
  • the method practically eliminates the misalignments of the discharge chamber and the light spot relative to the lamp base, which are caused by vibration, shock and similar mechanical effects. It has been shown that any relative movement between the lamp base and the discharge chamber is only due to the flexibility of the supporting legs of the clamp ring, but practically no relative movement could be observed between the clamp ring and the envelope. Further, it has been found that the proposed method allows generally larger tolerances in some other production steps, such as the positioning tolerances of the clamp support legs relative to the lamp base.

Landscapes

  • Non-Portable Lighting Devices Or Systems Thereof (AREA)
  • Fastening Of Light Sources Or Lamp Holders (AREA)
  • Manufacture Of Electron Tubes, Discharge Lamp Vessels, Lead-In Wires, And The Like (AREA)
  • Common Detailed Techniques For Electron Tubes Or Discharge Tubes (AREA)

Claims (17)

  1. Lampe à décharge (1) comprenant un conduit de décharge (2) scellé dans une enveloppe tubulaire (4), un culot (5) de lampe recouvrant une partie d'extrémité de l'enveloppe (4),
    des moyens de fixation permettant une fixation sensiblement rigide de l'enveloppe (4) sur le culot (5) de lampe, les moyens de fixation comprenant
    un anneau (6) de serrage en métal entourant une partie de l'enveloppe (4) à l'extérieur du culot (5) de lampe, caractérisé en ce que
    un revêtement (7) en matière plastique fondu est prévu entre l'anneau (6) de serrage et l'enveloppe (4), le revêtement (7) en matière plastique fondu remplissant de manière sensiblement complète un espace entre l'enveloppe (4) et l'anneau (6) de serrage.
  2. Lampe à décharge (1) selon la revendication 1, dans laquelle le diamètre interne (Dc) de l'anneau (6) de serrage est plus grand que le diamètre externe (De) respectif de l'enveloppe (4) de sorte que l'espace entre l'enveloppe (4), l'anneau (6) de serrage et le revêtement (7) en matière plastique entoure de manière sensiblement complète l'enveloppe (4).
  3. Lampe à décharge (1) selon la revendication 1 ou la revendication 2, dans laquelle la température de ramollissement du revêtement (7) en matière plastique est supérieure à 260 °C.
  4. Lampe à décharge selon l'une quelconque des revendications 1 à 3, dans laquelle le revêtement (7) en matière plastique est constitué d'un matériau en polyéther éther cétone (PEEC).
  5. Lampe à décharge selon l'une quelconque des revendications 1 à 4, dans laquelle l'anneau (6) de serrage est fixé sur le culot (5) de lampe avec des pattes métalliques (61).
  6. Lampe à décharge (1) selon la revendication 5, dans laquelle les pattes (61) sont soudées à une partie de surface externe de l'anneau (6) de serrage.
  7. Lampe à décharge (1) selon la revendication 5, dans laquelle les pattes (61) sont solidaires de l'anneau (6) de serrage.
  8. Lampe à décharge selon l'une quelconque des revendications 5 à 7, dans laquelle une extrémité (62) des pattes métalliques (61) est introduite par pression dans les fentes de réception correspondantes du culot (5) de lampe.
  9. Lampe à décharge selon l'une quelconque des revendications 5 à 7, dans laquelle le culot (5) de lampe est moulé autour d'une extrémité (62) des pattes métalliques (61).
  10. Procédé de fabrication d'une lampe à décharge,
    une lampe à décharge (1) comprenant
    un conduit de décharge (2) scellé dans une enveloppe tubulaire (4),
    un culot (5) de lampe recouvrant une partie d'extrémité de l'enveloppe (4),
    des moyens de fixation permettant une fixation sensiblement rigide de l'enveloppe (4) sur le culot (5) de lampe, les moyens de fixation comprenant un anneau (6) de serrage en métal entourant une partie de l'enveloppe (4) à l'extérieur du culot (5) de lampe,
    le procédé comprenant les étapes suivantes :
    ménager un espace entre l'anneau (6) de serrage et l'enveloppe (4),
    ménager un revêtement (7) en matière plastique thermofusible dans l'espace entre l'anneau (6) de serrage et l'enveloppe (4),
    faire fondre le revêtement (7) en matière plastique et remplir l'espace de manière sensiblement complète entre l'anneau (6) de serrage et l'enveloppe (4).
  11. Procédé selon la revendication 10, comprenant en outre les étapes suivantes :
    insérer le revêtement (7) en matière plastique dans l'anneau (6) de serrage, et insérer ensuite l'enveloppe (4) dans l'anneau (7) de serrage.
  12. Procédé selon les revendications 10 ou 11, comprenant également les étapes suivantes :
    régler une position de l'enveloppe (4) relativement sur le culot (5) de lampe avant de faire fondre le revêtement (7) en matière plastique et,
    après la fusion du revêtement (7) en matière plastique, conserver la position réglée de l'enveloppe (4) relativement au culot (5) de lampe pendant une période de refroidissement du revêtement (7) en matière plastique.
  13. Procédé selon la revendication 10, dans lequel la fusion du revêtement (7) en matière plastique s'effectue avec des rayons infrarouges, une flamme chauffante ou un champ électromagnétique H.F.
  14. Ensemble de fixation pour fixer une enveloppe de lampe à décharge sur un culot de lampe,
    comprenant :
    un anneau (6) de serrage en métal pour entourer une partie d'une l'enveloppe tubulaire (4),
    des pattes (61) fixées à l'anneau(6) de serrage avec une extrémité, et une autre extrémité (62) des pattes (61) qui s'étend à l'opposé de l'anneau (6) de serrage, et qui vient s'insérer dans un culot (5) de lampe, caractérisé en ce que l'anneau (6) de serrage comporte un revêtement (7) en matière plastique thermofusible.
  15. Ensemble de fixation selon la revendication 14, dans lequel le revêtement (7) en matière plastique est constitué d'un matériau en polyéther éther cétone (PEEC).
  16. Ensemble de fixation selon la revendication 14, dans lequel les pattes (61) sont soudées à une partie de surface externe de l'anneau (6) de serrage.
  17. Ensemble de fixation selon la revendication 14, dans lequel les pattes (62) sont solidaires de l'anneau (6) de serrage.
EP04250003A 2003-01-03 2004-01-02 Lampe a décharge comprenant un socle et procédé et fixation pour sa fabrication Expired - Fee Related EP1439569B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US336151 2003-01-03
US10/336,151 US7002285B2 (en) 2003-01-03 2003-01-03 Discharge lamp with bulb fixture arrangement and method for manufacturing the same

Publications (3)

Publication Number Publication Date
EP1439569A2 EP1439569A2 (fr) 2004-07-21
EP1439569A3 EP1439569A3 (fr) 2007-08-29
EP1439569B1 true EP1439569B1 (fr) 2008-11-05

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Application Number Title Priority Date Filing Date
EP04250003A Expired - Fee Related EP1439569B1 (fr) 2003-01-03 2004-01-02 Lampe a décharge comprenant un socle et procédé et fixation pour sa fabrication

Country Status (5)

Country Link
US (1) US7002285B2 (fr)
EP (1) EP1439569B1 (fr)
JP (1) JP3940722B2 (fr)
KR (1) KR100852472B1 (fr)
DE (1) DE602004017527D1 (fr)

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Also Published As

Publication number Publication date
EP1439569A3 (fr) 2007-08-29
JP3940722B2 (ja) 2007-07-04
KR100852472B1 (ko) 2008-08-18
EP1439569A2 (fr) 2004-07-21
US20040130255A1 (en) 2004-07-08
JP2004214202A (ja) 2004-07-29
KR20040062889A (ko) 2004-07-09
DE602004017527D1 (de) 2008-12-18
US7002285B2 (en) 2006-02-21

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